Flat cable and a manufacturing method thereof

ABSTRACT

A flat cable includes first and second insulator sheets, and a plurality of conductor elements arranged in parallel relation to one another over the length of the sheets. The first insulator sheet is provided with an adhesive layer. The conductor elements are interposed between the adhesive layer and the second insulator sheet. The first and second insulator sheets are first press-adhered under heat through the adhesive layer, and then bonded by an ultrasonic welding unit. The ultrasonic welding unit includes a horn for imparting ultrasonic oscillations, and an anvil placed in opposition to the horn. The first and second insulator sheets are bonded in the zones which extend along the length of the sheets and are located outside the loci where the conductor elements are arranged. The bonding is performed either continuously or in an intermittent manner. In a flat cable thus produced, the conductor elements embedded therein are efficiently prevented from mutual short-circuiting. Although the adhesive layer is made very thin, the insulator sheets are adhered to each other very firmly.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a method of manufacturing a flat electricalcable used e.g. for wiring public utility apparatuses, office automationapparatuses, electronic parts mounted in vehicles, and the like. Inparticular, the invention concerns devices used for the manufacture ofsuch a flat cable. The invention further concerns a flat cable producedby such a manufacturing method or device.

2. Description of Background Information

FIGS. 1A and 1B show how the prior art flat cables were manufactured inthe past. According to a known method, a pair of insulator films 100 isprepared, so that each includes a base film 101 and an adhesive layer102, the adhesive layers facing each other. A plurality of rectangularconductors 103 are then arranged parallel to one another, and areflanked by the pair of insulator sheets 100 over their length.Subsequently, the insulator sheets 100 are thermally bonded e.g. byheated rollers.

In the above manufacturing method, the adhesive layers 102 of theinsulator sheets 100 have to be sufficiently thick for each of therectangular conductors 103 to be deeply embedded in the adhesive layers102, with the insulator sheets 100 firmly adhered and bonded. To obtainsuch a result, the base film 101 and adhesive layer 102 of eachinsulator sheet 100 must usually have an approximate thickness of 50 μmand 60 μm, respectively.

In such a construction, because the adhesive layers 102 must havesubstantial thickness, material costs are relatively high. In addition,as the adhesive layers 102 usually employ combustible agents, a flatcable including such a thick adhesive layer 102 raises the problem ofinflammability.

Another flat cable manufacturing method is disclosed in Japanese PatentApplication published under No.2000-502 833, according to which therectangular conductors are initially arranged parallel to one anotherand sandwiched by two insulator sheets containing no adhesive layer, theinsulator sheets being bonded to each other by ultrasonic welding.

However, ultrasonic welding alone does not allow the insulator sheets tobe sufficiently well bonded, especially in the longitudinal zonesextending between the rectangular conductors contained in the flatcable. When the insulator sheets are only loosely adhered, they may formair gaps therebetween, into which water or moisture from condensationmay penetrate. Such a phenomenon creates a high risk of short-circuitingbetween the rectangular conductors.

In parallel, research is currently underway for a flat cable whichrequires a smaller space and weighs less. In this case too, the flatcable is manufactured by providing two insulator sheets, and interposingtherebetween a number of mutually parallel rectangular conductorelements over the length of the sheets. According to one of themanufacturing methods, the insulator sheets flanking the conductorelements are bonded by ultrasonic welding.

According to one of the known ultrasonic welding methods, the side edgesof insulator sheets which are positioned outside the parallel array ofconductor elements are bonded intermittently by ultrasonic welding alongthe length direction of the sheets. However, in such a flat cable,electrically conductive material such as water tends to penetratethrough non-bonded portions, thereby causing short circuits between theconductor elements.

The present invention aims at solving the problem caused by such anaccident-prone flat cable, and provides a method for its manufacture,according to which the insulator sheets are intimately and firmlyadhered through an adhesive layer, and, moreover, in which the adhesivelayer can be made as thin as possible.

The invention also aims to provide a system for producing a flat cable,in which newly conceived ultrasonic welding units are used.

Further, the invention aims at manufacturing a flat cable, in which theconductor elements are efficiently prevented from short-circuiting.

SUMMARY OF THE INVENTION

To this end, there is provided a method of manufacturing a flat cablehaving a length and a width, the flat cable including first and secondinsulator sheets, and at least one adhesive layer interposedtherebetween. The flat cable further includes a plurality of conductorelements arranged in parallel relation to one another over the length ofthe first and second insulator sheets. The method includes providing theadhesive layer on at least the first insulator sheet so as to face thesecond insulator sheet, interposing the conductor elements between theadhesive layer and the second insulator sheets, provisionally adheringthe first and second insulator sheets including the conductor elementsthrough the adhesive layer by means of heat pressing force exerted fromoutside the first and second insulator sheets, and bonding, byultrasonic welding, the first and second insulator sheets through thezones extending along the length thereof and located outside the lociwhere the conductor elements are arranged.

Preferably, the adhesive-layer providing includes providing a firstinsulator sheet having a thickness of about 12 to about 300 μm and anadhesive layer having a thickness of about 1 to about 3 μm.

Preferably yet, the adhesive-layer providing includes providing anadhesive layer formed of the same type of material as that of the firstinsulator sheet, the adhesive layer containing no halogen-basedflame-retardant.

Typically, the adhesive-layer providing includes providing the first andthe second insulator sheets, so that one of them is at least about 1.5times thicker than the other.

The invention also proposes a system for manufacturing a flat cablehaving a length and a width, the flat cable including first and secondinsulator sheets, and at least one adhesive layer interposedtherebetween. The flat cable further includes a plurality of conductorelements arranged in parallel relation to one another over the length ofthe first and second insulator sheets. The system includes, along aproduction flow line from upstream to downstream, an adhesiveapplication unit that provides the adhesive layer on at least the firstinsulator sheet so as to face the second insulator sheet, a conductorfeed unit that interposes the conductor elements between the adhesivelayer and the second insulator sheets, a provisional adhering unit thatprovisionally adheres the first and second insulator sheets includingthe conductor elements through the adhesive layer by a heat pressingforce exerted from outside the first and second insulator sheets, and anultrasonic welding unit that bonds the first and second insulator sheetsthrough the zones extending along the length thereof and located outsidethe loci where the conductor elements are arranged.

Preferably, the above ultrasonic welding unit includes a horn thatimparts ultrasonic oscillations, and an anvil located in opposition tothe horn. The horn includes an oscillation-imparting portion, with whichone of the first and second insulator sheets is placed into contact, andthe anvil has a generally cylindrical form and includes an axis arrangedperpendicularly to the production flow line, the anvil and being freelyrotatable around the axis. The generally cylindrical body includes anouter cylindrical face including an appropriate number of arrays ofprotrusions, the protrusions being aligned in the circumferentialdirection of the outer cylindrical face and extending at a giveninterval therealong, such that the arrays of aligned protrusions can beplaced into contact with the other of the first and second insulatorsheets at both sides of each of the conductor elements. Preferably yet,the ultrasonic welding unit includes a horn that imparts ultrasonicoscillations, and an anvil located in opposition to the horn. The hornincludes a plane, with which one of the first and second insulatorsheets is placed into contact over the width hereof. The anvil has agenerally cylindrical form that can rotate freely around an axis, theaxis being provided perpendicular to the production flow line, and theanvil includes an outer circular face including an appropriate number ofcircular ribs continuously extending in the circumferential directionthereof, such that the circular ribs can be placed into contact with theother of the first and second insulator sheets at both sides of each ofthe conductor elements.

Each of the circular ribs may have an alternating broad and narrowwidth.

Typically, the ultrasonic welding unit includes first and second hornsthat impart ultrasonic oscillations, located respectively upstream anddownstream on the production flow line at a given distance, and furtherincludes corresponding first and second anvils located in opposition tothe first and second horns. The first and second horns respectivelyinclude an oscillation-imparting generally cylindrical body, thegenerally cylindrical body having an axis arranged perpendicularly tothe production flow line and being freely rotatable around the axis.Each of the oscillation-imparting cylindrical bodies has an outercylindrical face including an appropriate number of arrays ofprotrusions aligned in the circumferential direction thereof andextending at a given interval therealong, such that the arrays ofprotrusions can be placed into contact with one of the first and secondinsulator sheets at both sides of each of the conductor elements. Thefirst and second anvils are fixedly positioned and respectively includea plane, with which the other of the first and second insulator sheetsis placed into contact, so that the first horn and anvil can form, byultrasonic welding, a first series of intermittent bonded portions witha given interval therebetween, and the second horn and anvil then form asecond series of bonded portions in the given interval.

Alternatively, the ultrasonic welding unit may include a horn thatimparts ultrasonic oscillations, and an anvil located in opposition tothe horn, the horn and anvil including respective planes opposing eachother. The opposing planes of the horn and anvil include, respectively,an appropriate number of arrays, respectively formed of protrusions andrecesses, each of the protrusions having the same gauge as each of therecesses along the length of the first and second insulator sheets, suchthat the arrays of the opposing face of the horn and those of the anvilcan be placed into contact respectively with the first and secondinsulator sheets at both sides of each of the conductor elements. Thus,the first and second insulator sheets can be flanked by the arraysformed of protrusions and recesses of the horn and of the anvil, andsubjected to a first ultrasonic welding, thereby forming intermittentfirst bonded portions, and the first and second insulator sheets can bemoved by a distance equivalent to the gauge, and the first and secondinsulator sheets can be further subjected to a second ultrasonicwelding, thereby forming second bonded portions that link the firstbonded portions.

Alternatively yet, the ultrasonic welding unit may include a horn thatimparts ultrasonic oscillations, and an anvil located in opposition tosaid horn. One of the horn and the anvil has a plane with a length whichextends along the length of the first and second insulator sheets, whilethe other includes a cylindrical body having an axis arrangedperpendicularly to the production flow line and being freely rotatablearound the axis, the cylindrical body being movable back and forth alongthe production flow line. Additionally, the cylindrical body has anouter cylindrical face including an appropriate number of circular ribsextending in the circumferential direction of the outer cylindricalface, so that the circular ribs can be placed into contact with thefirst and second insulator sheets at both sides of each of the conductorelements.

As a variant, each of the circular ribs may have an alternating broadand narrow width, or each of the circular ribs may be provided withrecesses.

A further object of the invention is to provide a flat cable includingfirst and second insulator sheets having a length and a width, andcontaining a plurality of conductor elements arranged in parallelrelation to one another over the length of the first and secondinsulator sheets. The flat cable further includes an adhesive layerwhich bonds the first insulator sheet, the second insulator sheet andthe conductor elements interposed therebetween, by means of heatpressing.

In the above flat cable, the first and second insulator sheets arebonded at the zones extending along the length thereof and are locatedoutside the loci where the conductor elements are arranged.

As a variant, each of the zones may be bonded in an intermittent way, orin a continuous way.

Preferably, the adhesive layer includes the same type of material asthat of the first insulator sheet, the adhesive layer containing nohalogen-based flame-retardant.

Typically, one of the first insulator sheet and the second insulatorsheet is at least 1.5 times thicker than the other.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and the other objects, features and advantages of the presentinvention will be made apparent from the following description of thepreferred embodiments, given as non-limiting examples, with reference tothe accompanying drawings, in which:

FIG. 1A is a cross-sectional view of rectangular conductor wiresinterposed between two insulator films in the prior art flat cable;

FIG. 1B is a cross-sectional view of the flat cable when the insulatorfilms are adhered;

FIG. 2 is a schematic horizontal view of a production flow line for aflat cable according to the invention;

FIG. 3 is a cross-sectional view of the rectangular conductor elementsand insulator sheets at a production stage of a flat cable according tothe invention;

FIG. 4 is a cross-sectional view of the rectangular conductor elementsand insulator sheets at a subsequent production stage;

FIG. 5 is a cross-sectional view of the conductor elements and insulatorsheets when they are bonded by ultrasonic welding;

FIG. 6 is a perspective, partially cut-away view of the resultant flatcable;

FIG. 7 is a cross-sectional view of a flat cable manufactured accordingto a first variant method;

FIG. 8 is a cross-sectional view of a flat cable manufactured accordingto a second variant method;

FIG. 9 is a perspective view of a flat cable manufactured according to athird variant method;

FIG. 10 is a cross-sectional view of a flat cable manufactured accordingto a fourth variant method; and

FIG. 11 is a cross-sectional view of a flat cable manufactured accordingto a fifth variant method.

FIG. 12 is a side elevational view of an ultrasonic welding unitaccording to a first variant embodiment;

FIG. 13 is an enlarged view of a horn employed in the unit of FIG. 12;

FIG. 14 is a left-hand side view of the horn of FIG. 13;

FIG. 15 is an enlarged elevational view of an anvil employed in the unitof FIG. 12;

FIG. 16 is a left side view of the anvil of FIG. 15;

FIG. 17 is a top plan unit view of a flat cable produced by the firstvariant ultrasonic welding unit;

FIG. 18 is a side elevational view of the anvil contained in anultrasonic welding unit according to a second variant embodiment;

FIG. 19 is a top plan view of a flat cable produced by the secondultrasonic welding unit;

FIG. 20 is a side elevational view of the anvil contained in anultrasonic welding unit according to a third embodiment;

FIG. 21 is an elevational view of an ultrasonic welding unit accordingto a fourth embodiment;

FIG. 22 is a left side view of an oscillation-imparting body of theultrasonic welding unit of FIG. 21;

FIG. 23 is a top plan see-through view of a flat cable partially bondedby the ultrasonic welding unit of FIG. 21;

FIG. 24 is a top plan view of a flat cable produced by the ultrasonicwelding unit of FIG. 21;

FIG. 25 is a perspective view of an ultrasonic welding unit according toa fifth embodiment;

FIGS. 26 to 29 are the views of sequential operational steps, in which ahorn and an anvil are handled according to a variant embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 2 shows a system for manufacturing a flat cable of the invention.The system includes several devices arranged along a production flowline P extending from an upstream side (left-hand side in FIG. 2) to adownstream side (right-hand side in FIG. 2). The production flow line Pis provided, at the upstream side, with a conductor feed unit includinga plurality of conductor feed rollers 10, from which are released theconductor elements 5 (e.g. conductor wires). The conductor feed rollers10 are followed by pitch rollers 11 which dispose the conductor elements5 at a given pitch, and further by a pair of sheet feed rollers 12 and13, and heat press adhering units 12 a and 13 a, all of which aresequentially arranged along the production flow line P from upstreamtoward downstream.

Each conductor feed roller 10 stores a coiled conductor wire 5 made, forexample, of copper or a copper alloy. The conductor elements 5 areprovided in a number corresponding to the number of the conductorelements 5 to be arranged in parallel to each other and embedded in aflat cable 6. In the present example, four conductor elements 5 areformed into a flat cable 6. Thus, there are provided four conductor feedrollers 10 in the production flow line P. Further, in this example, theconductor elements 5 used each have a rectangular cross-section, asshown in FIG. 3, although any suitable cross-section may be used.

The conductor elements 5 drawn on the corresponding conductor feedrollers 10 are aligned parallel to one another through the pitch rollers11, and fed into the heat-press adhering units 12 a and 13 a.

The sheet feed rollers 12 and 13 are e.g. installed respectively belowand above the production flow line P. First and second insulator sheets1 and 4 have a band-like shape, and are coiled and stored around therespective sheet feed rollers 12 and 13.

In the present embodiment, only the first insulator sheet 1 is providedwith an adhesive layer. The sheet is coiled around a first sheet feedroller 12 located below the production flow line P. Conversely, thesecond insulator sheet 4 includes no adhesive layer. The second sheet iscoiled around a second sheet feed roller 13 located above the productionflow line P (shown upside down in FIG. 2). The first insulator film 1thus includes a base film 2 and an adhesive layer 3. The base film 2 isformed of a suitable flexible and ultrasonically fusible resin, e.g.polyethylene terephthalate (PET). One face thereof (the face to beadhered to the second insulator film 4) is provided with a thermoplastic(hot melt type) adhesive layer 3, by an adhesive application unit (notshown), e.g. by painting or spraying. The adhesive layer 3 is appliedwith any conventional adhesive application device known to those skilledin the art, and is not illustrated in the drawings. The second insulatorsheet 4—which has no adhesive layer—just contains a base film formed ofa flexible resin. Alternatively, an adhesive layer 3 may of course beprovided on both insulator sheets 1 and 4, although their productioncosts become higher. The first insulator sheet 1 (with adhesive layer)and the second insulator sheet 4 (without adhesive layer) are then drawnout from the sheet feed rollers 12 and 13 respectively, and sent to theheat-press adhering units 12 a and 13 a.

The heat-press adhering units 12 a and 13 a form a provisional adheringunit and include a first heat adhesion roller 12 a located below theproduction flow line P and a second heat adhesion roller 13 a locatedabove line P. The first and second insulator sheets 1 and 4 aresuperposed and introduced between the first and second heat pressadhesion rollers 12 a and 13 a. The sheets 1 and 4 are thus heat adheredthrough the adhesive layer 3.

As shown in FIG. 2, the second insulator sheet 4 coiled around the sheetfeed roller 13 located above the production flow line P, is thensuperposed from above (shown upside down in FIG. 3) onto the conductorelements 5 aligned in parallel, while the first insulator sheet 1, whichis wound around the sheet feed roller 12 located below the productionflow line P, is superposed from below (shown upside down in FIG. 3) ontothe same conductor elements 5. The insulator sheets 1 and 4 flanking theconductor elements 5 are then introduced between the first and secondheat adhesion rollers 12 a and 13 a, and hot-pressed therebetween. Asshown in FIG. 4, the insulator sheets 1 and 4 wrap the aligned conductorelements 5, and are provisionally heat-adhered to each other through theheat adhesion layer 3. At the same time, the insulator sheets 1 and 4are firmly heat-adhered to the conductor elements 5 through the heatadhesion layer 3 (provisional adhesion).

The provisionally heat-adhered insulator sheets 1 and 4, which hold theconductor wires 5, are then sent to an ultrasonic bonding unit US.

As shown in FIGS. 2 and 5, the ultrasonic bonding unit US includes anoscillation-imparting horn 14 located above the production flow line P,and an ultrasonic anvil 17 located below the line P.

The oscillation-imparting horn 14 has an oscillation imparting portion14 a formed into a straight-line plane over the width of the secondinsulator sheet 4, the length of the plane being greater than the widthof the sheet 4 (refer to FIGS. 13 and 14 infra). Theoscillation-imparting portion 14 a is provided perpendicularly to theupper face of the second insulator sheet 4, which moves along theproduction flow line P, such that it can rub along over the whole widthof the second insulator sheet 4. The ultrasonic oscillations generatedby a an ultrasonic oscillation-generating mechanism e.g. oscillator, areimparted to the oscillation-imparting horn 14. The latter 14 isconfigured so as to oscillate over the width of the second insulatorsheet 4.

The ultrasonic anvil 17 has a generally cylindrical shape including anouter cylindrical face and an axis 17 b. The outer cylindrical face isprovided with several arrays of protrusions 17 a aligned in thecircumferential direction thereof, which are to be placed into contactwith the first insulator sheet 1. Each array of protrusions isconfigured so as to surround the cylindrical face at a given pitch inthe circumferential direction, defining a toothed wheel shape, such thatthe positions of those arrays of protrusions 17 a correspond to thespaces between the parallel-aligned conductor elements 5, as well as tothe two side edges of the first insulator sheet 1. The axis 17 b of theultrasonic anvil 17 is placed perpendicularly to the production flowline P, at a position therebelow. The ultrasonic anvil 17 is held aroundthe axis 17 b in a freely rotatable way. When the first insulator film 1is advanced along the production flow line P, the arrays of protrusions17 a formed on the outer cylindrical face of the ultrasonic anvil arepressed onto the external face (bottom face) of the first insulator film1. Accordingly, as the first insulator film 1 advances, the ultrasonicanvil rotates in synchronization with its advancement, by frictionaldragging effect or by being driven by a rotation driver (not shown infigures).

When the insulator films 1 and 4 holding a plurality of conductorelements 5 are heat pressed and introduced between theoscillation-imparting horn 14 and the ultrasonic anvil 17, theoscillation-imparting portion 14 a of the horn 14 rubs against theexternal face (top face) of the second insulator sheet 4 over the entirewidth thereof. At the same time, the arrays of protrusions 17 a of theultrasonic anvil 17 are placed under the oscillation-imparting portion14 a, and placed into contact with the external face of the firstinsulator sheet 1. The ultrasonic oscillation energy is imparted to theinsulator sheets 1 and 4, while the latter are pressed against eachother. As shown in FIG. 6, the insulator sheets 1 and 4 are bonded byultrasonic welding in the zones extending circumferentially outside theparallel-aligned conductor elements 5. As the insulator sheets 1 and 4move on, the oscillation-imparting portion 14 a of theoscillation-imparting horn 14 rubs against the external face of thesecond insulator sheet 4, while the arrays of protrusions 17 a of theultrasonic anvil 17 are intermittently and sequentially placed intocontact with the external face of the first insulator sheet 1. Theinsulator sheets 1 and 4 are thus bonded by ultrasonic welding throughintermittent loci extending along the longitudinal direction of theinsulator sheets 1 and 4 (ultrasonic welding).

Finally, the two side edges of the insulator sheets 1 and 4 are cut offby blades 18. The resulting flat cable 6 is then wound around a coilingroll 20.

According to the above production method, the conductor elements 5 arearranged parallel to one another, and interposed between the insulatorsheets 1 and 4. The latter are first heat pressed against each other,and then bonded by ultrasonic welding to form a flat cable 6.

In the flat cable 6 thus produced, the insulator sheets 1 and 4 arebonded by ultrasonic welding in the zones outside the loci where theconductor elements 5 are arranged in parallel, so that the insulatorsheets 1 and 4 can be bonded with a sufficient bonding force. Moreover,the bonding is effected by ultrasonic spot welding through loci S, sothat, when the flat cable 6 is to be parted or peeled, the insulatorsheets 1 and 4 can be easily separated from each other.

As the insulator sheets 1 and 4 are press-adhered under heat prior toultrasonic welding, by heat adhesion rollers 12 a and 13 a, they can bebonded more snugly compared to a mere ultrasonic welding: both insulatorsheets 1 and 4 are firmly and intimately adhered, avoiding the formationof air gaps. Moreover, as the insulator sheet 1 and the conductorelements 5 are adhered through the adhesive layer 3, these conductorelements 5 cannot be displaced easily from the positions where they arefixed by the insulator sheets 1 and 4.

Further, the ultrasonic welding produces a strong adhesive force betweenthe insulator sheets 1 and 4. The adhesive layer 3 therefore only needsto be thick enough to secure the adhesion between the insulator sheets 1and 4. The thickness of the adhesive layer 3 can thus be reduced to aminimum, compared to the prior art example shown in FIGS. 1A and 1B.

In practice, when the base film 2 of the insulator sheet 1 has athickness of 12 to 300 μm, preferably 25 to 100 μm, the adhesive layer 3may have a thickness of 1 to 3 μm.

As the adhesive layer 3 can be made thinner than in the prior art, useof inflammable adhesive agents can be reduced to a minimum, and the flatcable 6 thus manufactured procures a good flame resistance.

In the prior art example shown in FIGS. 1A and 1B, the adhesive layercontains a halogen-containing flame retardant in order to procure asufficient resistance to flame. When such adhesive layers are scrapped,they generate halogen gas and raise environmental problems. By contrast,the present manufacturing method already confers to the flat cable 6 agood flame resistance, and allows using an adhesive agent containing nohalogen compound. In addition, the inventive adhesive layer 3 can bemade of an adhesive agent having the same type of material as that ofthe base film 2. Recycling processes of flat cables 6 can thus begreatly simplified. Examples of such an insulator sheet 1 include one inwhich the base film 2 is made of a polyester-type resin e.g.polyethylene terephthalate (PET) and polybutylene terephthalate (PBT),while the adhesive layer 3 is made of a polyester-type adhesive agente.g. polyester elastomer. In another example, the base film 2 is formedof a polyolefin-type resin, e.g. polyethylene, while the adhesive layer3 is formed of a polyolefin-type adhesive agent, e.g. ethylene-vinylacetate polymer (EVA). In the above cases, the base film 2 and theadhesive layer 3 can be treated as similar material, and recycled andregenerated in a same handling way.

In variant embodiments described infra, the component elementscorresponding to those already mentioned in the preceding embodiment arereferred to with the same reference numbers. Only the new elements areexplained specifically.

In a first variant embodiment of a first aspect of the invention (FIG.7), a transparent insulator sheet 4B containing no adhesive layer isused as the second insulator sheet 4, the transparent insulator film 4Bbeing formed of a transparent resin such as polyethylene terephthalate(PET), 1-(N-phenylamino)naphthalene (PA), polycarbonate (PC), etc.

In the prior art case shown in FIGS. 1A and 1B, both insulator sheets100 contain a respective adhesive layer 102. The insulator sheets 100thus constructed tend to become opaque, typically because of thenon-transparency of the adhesive layers 102. By comparison, the presentinvention enables use of the second insulator sheet 4 free of adhesivelayer. Accordingly, this embodiment makes it much easier to create atransparent insulator sheet 4B merely by using a transparent resin anddoing away with adhesive layer.

When the transparent insulator sheet 4B is used, the condition of theinner zone between the insulator sheets 1 and 4B can be observeddirectly from outside, through the transparent insulator sheet 4B.Undesirable inclusions, irregularities of the conductor elements and thelike can thus be easily detected. Further, the front side and reverseside of the manufactured flat cable 6B can be easily recognized. As aresult, for each flat cable 6B, the connecting points at both ends ofeach conductor element 5 can be observed very easily.

In a second variant method (see FIG. 8), the first insulator sheet 1,including an adhesive layer in the above embodiments, is further coatedwith a thermoplastic adhesive layer over its external face (firstexternal adhesive layer 51C), so as to form a first coated insulatorsheet 1C. Typically, the second insulator sheet 4, which includes noadhesive layer in the preceding embodiments, is also coated with athermoplastic adhesive layer over its external face (second externaladhesive layer), so as to form a second coated insulator sheet 4C. Whenthe heat-press adhesion is performed, the adhesive layer 3 between thecoated insulator sheets 1C and 4C is melted down and does not appearbeside the conductor elements 5 (see FIG. 8).

When the flat cable 6C thus prepared is fitted into a counter-partfitting, e.g. a connector box in an apparatus, it can easily be fittedwith the fitting through the external adhesive layers 51C and 52C.

In the preceding embodiment, when the coated insulator sheets 1C and 4Care thermally adhered, the external adhesive layers 51C and 52C may meltdown together with the adhesive layer 3. Such a situation can be avoidedby finishing the outer cylindrical face of the heat rollers 12 a and 13a with e.g. a silicone resin, so that the surface become non-adhesiveand the external adhesive layers 51C and 52C, even if melted, are notglued to the heat rollers 12 a and 13 a. In the same manner, theadhesive agent used for the external adhesive layers 51 C and 52C may bechosen from among compounds having a melting point higher than that ofthe adhesive agent used in the adhesive layer 3 for bonding theinsulator sheets 1C and 4C.

In a third variant shown in FIG. 9, the thickness hi of the insulatorsheet 4D, which corresponds to the insulator sheet 4 without adhesivelayer in the first embodiment, may be set to be at least 1.5 times thethickness h2 of the base film of the insulator sheet 1D, whichcorresponds to the insulator sheet 1 with adhesive layer in the firstembodiment. Alternatively, the thickness h2 may be at least 1.5 timesthe thickness h1.

In such a configuration, when the end portions of the finished flatcable 6D are made into terminals to be inserted into connectors, onlythe thinner insulator sheet, e.g. the first insulator sheet 1D, needs tobe stripped off at the end portions, while the thicker insulator sheet4D may be left as it stands. In such a case, the end portions of theflat cable 6D, though not reinforced by a supporting plate, may be madeinto terminals, the latter being sufficiently resistant to bending wheninserted into connectors.

In a fourth variant shown in FIG. 10, the width of the insulator sheet4E, which corresponds to the insulator film 4 in the first embodiment,is set to be greater than that of the insulator sheet 1E, whichcorresponds to the insulator sheet 1 in the first embodiment. When bothinsulator sheets 1E and 4E are bonded, the two side edges 4Ea ofinsulator sheet 4E extend outwardly, are bent upwardly (when viewed inFIG. 10), and superposed over the corresponding two side edges of theinsulator sheet 1E. The corresponding side edges are then bondedthrough, e.g. the thermoplastic adhesive agent, thereby forming a flatcable 6E.

In the above case, both side edges of the flat cable 6E form a smoothrounded edge, which has advantages of giving a soft touch feeling andalso facilitates handling. Further, the side edges of the flat cable 6Eare strengthened by the side edges 4Ea of the insulator sheet 4E, sothat the flat cable 6E becomes more resistant to torsional stress.Furthermore, the end portions of the flat cable 6E will not be distortedwhen inserted into connectors.

In a flat cable 6F of a fifth variant (FIG. 11), insulator sheets 1F and4F may be made slightly wider than the insulator sheets 1 and 4 of thefirst embodiment, and joined slightly biased to each other in theirwidth direction. A side edge 1Fa of e.g. the insulator sheet 1F, whichhangs over the corresponding side edge of the insulator sheet 4F, maythen be bent downwardly (as viewed in FIG. 11) and superposed on thelatter 4F. They may be then bonded by means of a thermoplastic adhesiveagent. A side edge 4Fa of the insulator sheet 4F may be processedlikewise, and adhered to the insulator sheet 1F.

Such a structure confers the flat cable 6F with the same effect as inthe fourth variant case shown in FIG. 10. Moreover, as the insulatorsheets 1F and 4F may have the same width, the number of componentelements can be reduced, and manufacturing costs can be lowered.

A second aspect of the invention generally pertains to the ultrasonicwelding unit employed in the production flow line P mentioned for thefirst aspect of the invention.

In the first aspect of the invention, the anvil used carries a pluralityof arrays of protrusions aligned on its cylindrical face. By contrast,the anvil mentioned hereafter is designed to form a plurality ofcontinuous circular ribs, while preserving the possibility of varyingthe width of the ribs along the circumferential direction.

As shown in FIGS. 12 and 15, the anvil 15 of a first variant ultrasonicwelding unit also has a generally cylindrical form, the axis 15 a ofwhich is spaced downwardly from the production flow line P, andpositioned perpendicularly thereto. The anvil 15 is freely rotatablearound the cylinder axis 15 a. The outer cylindrical face of the anvil15 carries several circular ribs 16, each of which extends along thecircumferential direction, while alternating the size of the rib width.To this end, each circular rib 16 is provided with an alternating widerib portion 16 a and narrow rib portion 16 b, at a given pitch along thecircular direction. Further, the circular ribs 16 are arrangedwidthwise, so that they are positioned between the conductor elements onthe one hand, and at the two side edges of the sheets on the other, whenthese sheets are passed through.

When the insulator sheets 1 and 4 are advanced along the production flowline P, the circular ribs 16 are placed into contact with the insulatorsheet 1 located below the production flow line P. The anvil 15 is thusrotated through dragging, or can be rotated by a driving device (notshown in the figures) in synchronization with the supply speed of theinsulator sheets 1.

The insulator sheets 1 and 4 including the conductor elements 5 are thussent between the horn 14 and the anvil 15, while the horn 14 is impartedwith ultrasonic oscillations. Accordingly, the oscillation-impartingportion 14 a of the horn 14 (shown in FIGS. 13 and 14) rubs against overthe whole width of the insulator sheet 4 located above the productionflow line P, while the circular ribs 16 of the anvil 15 are positionedright beneath the oscillation-imparting portion 14 a and placed intocontact with the insulator sheet 1 located below the production flowline P. In this condition, the circular ribs 16 are placed outside thezones where the conductor elements 5 are arranged in the flat cable.Thereafter, the insulator sheets 1 and 4 are first adhered underpressure. Ultrasonic oscillation energy is then imparted to theinsulator sheets 1 and 4, and the latter are bonded through welding(FIG. 17).

As the insulator sheets 1 and 4 move on, the oscillation-impartingportion 14 a of the horn 14 rubs along the outer face of the insulatorsheet 4 located above the production flow line P. Simultaneously, thecircular ribs 16 of the anvil 15 are placed into contact with the outerface of the insulator sheet 1 located below the production flow line P.The insulator sheets 1 and 4 are thus continuously bonded by ultrasonicwelding along the length direction of the sheets 1 and 4.

A flat cable 6 thus formed by welding is sent to a guide roller 19, andwound around a coiling roll 20.

According to the above method including stepwise manufacturing, theinsulator sheets 1 and 4 of the flat cable 6 are continuously welded atboth sides of each conductor element 5 along the length direction of thesheets 1 and 4. An additional advantage of the first variant embodimentis that, even when electro-conductive contaminants e.g. water enter intothe flat cable 6, each conductor element is efficiently prevented fromshort-circuiting with another conductor element 1 by intercalatingcontinuous weld-bonding.

As shown in FIG. 17, the ultrasonically welded zone 21 includes widewelded portions and narrow welded portions. The insulator sheets 1 and 4are thus bonded firmly adhered to each other, while preserving thefeature that these sheets 1 and 4 can be easily detached at their endportions. This is a noteworthy advantage compared to a structure inwhich the welded zone has a wide welded portion all along the sheetlength.

By comparison, FIG. 18 shows a second variant ultrasonic welding unit,in which the circular ribs 16 of the anvil 15 are provided with the samewidth all along the circumferential direction of the ribs 16. The otherconstructional elements are the same as in the first variant embodiment.

As shown in FIG. 19, the flat cable 6 according to the second variantmeans includes a welded zone 21 having the same width over the lengthdirection of the flat cable 6. As in the first variant, even when wateror other electro-conductive contaminants enter into the flat cable 6,each conductor element is efficiently prevented from short-circuitingwith another conductor element 1 by intercalating continuously weldedbonds.

FIG. 20 shows a third variant ultrasonic welding unit, in which thecircular ribs 16 of the anvil 15 have the same width along thecircumferential direction of the ribs 16, as in the second variant.However, the circular ribs 16 are provided with recesses 16 c at a givenpitch along the circumferential direction. The pitch between therecesses 16 c may be chosen as a function of a balance desired to beestablished between the adhesion strength and the peeling facility. Theother construction components are the same as in the first variantmeans.

The flat cable 6 produced in the third variant means includes weldedzones 21 having varying welded surfaces along their length, and producesthe same effect as in the first variant.

FIG. 21 shows a fourth variant ultrasonic welding unit of the invention,in which the same construction components are referred to with the samereferences as in the first variant of the invention.

In this embodiment, the ultrasonic welding unit US includes an upstreamhorn 24 and a downstream horn 25 (located at a given distance downstreamalong the production flow line P), respectively imparting ultrasonicoscillations to the insulator sheets 1 and 4. The ultrasonic weldingunit US further includes a corresponding upstream anvil 26 anddownstream anvil 27.

The upstream anvil 26 and the downstream anvil 27 are fixedly installed,and include respectively a plane top face which is placed into contactwith the insulator sheet 1 located below the production flow line P.

The upstream horn 24 and the downstream horn 25 include correspondingoscillation-imparting bodies 29 and 30 having a cylindrical form, theaxes 29 a and 30 a of which are spaced upwardly from the production flowline P and placed perpendicularly thereto.

As shown in FIG. 22, the outer circular faces of theoscillation-imparting bodies 29 and 30 are provided withcircumferentially aligned protrusions 31 and 32, which extend around theoscillation-imparting body 29 or 30 at a given pitch. Thesecircumferentially-aligned protrusions 31 and 32 are arranged such that,when they are placed into contact with the insulator sheet 4, they arepositioned at opposite sides of each conductor element 5.

As shown in FIG. 23, the upstream horn 24 and upstream anvil 26 form,between the insulator sheets 1 and 4, the first welded portions 33 whichextend along the length direction of the sheets 1 and 4 at a givenpitch. The spaces between the first welded portions 33 are then filledwith second welded portions 34 by means of the downstream horn 25 anddownstream anvil 27, as shown in FIG. 24.

According to the above method and device, the zones of insulator sheets1 and 4 which flank each conductor element 5 are sequentially weldedfirst by the upstream horn 24 and anvil 26, then by the downstream horn25 and anvil 27. The respective welded portions 33 and 34 formcontinuous welded zones along the length direction of the sheets 1 and4. Such a construction has the advantage of protecting the flat cable 6from water or other contaminant penetration, and the conductor elements5 from short-circuiting. Further, the above method and device allowformation of a circular rib which has alternating broad and narrow ribwidths, in a very simple way.

More particularly, when the protrusions 31 of a firstoscillation-imparting body 29 have a wider size, while the protrusions32 of a second oscillation-imparting body 30 have a narrower size, theobtained insulator sheets 1 and 4 obtain a good adhesive force betweenthe sheets 1 and 4, while enabling an easy peeling-off at the endportions of the sheets 4, as in the case of the first variant.

FIG. 25 shows a fifth variant embodiment of the ultrasonic welding unitUS, in which the same construction components as in the first variantare referred to with the same numbers.

In this embodiment, the horn 36 and anvil 37 constituting an ultrasonicwelding unit US are respectively provided with rectangular blocks 38 and39 on their opposing inner faces. The rectangular blocks 38 and 39 areplaced into contact with the corresponding insulator sheets 1 and 4 atopposite sides of each conductor element 5. Each rectangular block 38 or39 has a side line placed in parallel relation to the production flowline P, the side line having a size S. Likewise, the space between tworectangular blocks has a corresponding side line having a size T.

A rectangular block 38 of the horn 36 and the corresponding rectangularblock 39 of the anvil 37 flank the two insulator sheets 1 and 4 and bondthem by ultrasonic welding, so as to form intermittent first weldedportions 33 as shown in FIG. 23. The insulator sheets 1 and 4 are thenadvanced by the distance T. Subsequently, the rectangular blocks 38 and39 flank the insulator sheets 1 and 4 and bond them by ultrasonicwelding, so that the troughs in the blocks formed by preceding weldingare fully or partially filled with second welded portion 34. When size Sis equal to size T, the welded portions form a continuous welded line.

The insulator sheets 1 and 4 are then moved by distance L, whichcorresponds to the side length of the horn 36 and anvil 37 along theproduction flow line P, and the same operation is repeated.

More particularly, the insulator sheets 1 and 4 are first ultrasonicallywelded by the rectangular blocks 38 and 39 of the corresponding horn 36and anvil 37 at both sides of each conductor element 5 embedded in theflat cable 6. The insulator sheets 1 and 4 are then moved by distance Tand further welded by the same method. The first and second weldedportions 33 and 34 thus formed make a continuous welded zone. Such acontinuous welded zone can efficiently protect the flat cable 6 fromwater or other conductor contaminants and the conductor elements 5 fromshort-circuiting, as mentioned already.

FIGS. 26 to 29 show a sixth variant embodiment of the ultrasonic weldingunit US, in which the same construction components as in the firstvariant embodiment are referred to with the same reference numbers.

In this embodiment, the upper face of the anvil 41 in the ultrasonicwelding unit US forms a plane having a given side length along theproduction flow line P. On the other hand, the horn 42 used is the sameas the one shown for the fourth variant. Namely, the horn 42 includes anoscillation-imparting body 43 having a cylindrical form. It is supportedby an axis located perpendicular to the production flow line P, in afreely rotatable way. The horn 42 together with theoscillation-imparting body 43 can be freely moved back and forth alongthe production flow line P.

The outer circular face of the oscillation-imparting body 43 isconstructed so as to form the anvil 15 in the first variant ultrasonicwelding means. Namely, it is provided with protrusions 16 aligned in thecircumferential direction. These protrusions 16 are adapted to be placedinto contact with the second (top-side) insulator sheet 4, on oppositesides of each conductor element 5.

As shown in FIG. 26, the horn 42 is placed over the anvil 41 at itsupstream side on the production flow line P. The horn 42 is then moveddownstream where the insulator sheets 1 and 4 are not yet welded.

As shown in FIG. 27, the horn 42 is moved up to the downstream end ofthe anvil 41, the insulator sheets 1 and 4 being ultrasonically weldedalong the way.

As shown in FIG. 28, the insulator sheets 1 and 4 are moved by apredetermined distance along the production flow line P, while the horn42 is slightly raised. In this manner, the advancing edge of theinsulator sheets 1 and 4 to be subsequently welded is positioned at thedownstream end of the anvil 41.

As illustrated in FIG. 29, the horn 42 is then moved back to theupstream side of the anvil 41, while the insulator sheets 1 and 4 areultrasonically welded by the horn 42 and anvil 41.

By repeating the above procedure, the insulator sheets 1 and 4 areultrasonically welded through a batch process, by the unit of apredetermined fraction.

According to the present embodiment, the welded portion of the flatcable 6 forms a continuous zone along the length direction of the flatcable 6. Such a structure has the same advantage as mentioned for thesecond variant.

Moreover, the outer cylindrical face of the oscillation-imparting body43 may be provided with the aligned protrusions 16 with the widths ofthe ribs varied, as in the first variant embodiment. The insulatorsheets 1 and 4 then obtains a good mechanical strength, while preservinga balanced peeling facility at the sheet end portions.

Alternatively, the outer cylindrical face of the oscillation-impartingbody 43 may also be configured as that of the second and third variantof the invention.

In the above sixth ultrasonic welding unit, the horn 42 is designed as amobile unit. However, the configuration of the horn 42 and that of theanvil 41 may be reversed in the above construction. Namely, the horn 42may be configured so as to have a given length along the production flowline P, while the anvil 41 may be configured like the anvil 15 in thefirst, second and third variants, which moves freely back and forthalong the production flow line P.

In each of the above embodiments, four conductor elements 5 are embeddedin a flat cable. However, the number of conductor elements is notspecifically limited, and may be five or any other appropriate numbers.

As can be understood from the inventive method described above (firstaspect of the invention), a pair of insulator sheets is provisionallyadhered by a hot-press procedure, and then bonded by ultrasonic welding.As a result, the insulator sheets can be bonded very firmly andintimately, even if the adhesive layer applied is very thin.

When manufacturing an insulator sheet coated with an adhesive layer byapplying the above method, the base film (one constituent of the abovesheet) may be about 12 to about 300 μm thick, while the adhesive layer(another constituent) may be as thin as about 1 to about 3 μm.

As the adhesive layer is so thin, its material may be the same as thatfor the base film, and need not include any halogen-containingretardant. The resultant flat cable is thus flame resistant, easilyrecyclable and generates no halogen gas upon burning.

Further, the thickness of one of the two insulator sheets (measured forthe base film, as the case may be) may be at least 1.5 times that of theother sheet. The end portions of the manufactured flat cable may then bemade into terminals which are to be inserted into connectors. To dothis, only the thinner insulator sheet is stripped off, preserving thethicker insulator sheet as it is. The terminals thus prepared can beinserted easily into the connectors without being distorted.

The ultrasonic welding unit includes a horn which imparts ultrasonicoscillations, and an anvil arranged in opposition to the horn. The hornhas a contact plane that extends over the width of the insulator sheetsand is placed into contact with one of the insulator sheets. The anvilhas a cylindrical form that can freely rotate around an axis. This axisis arranged in a direction perpendicular to the direction of motion ofthe insulator sheets. The outer circular face of the anvil may includean appropriate number of arrays of continuous circular ribs or alignedprotrusions arranged in the circumferential direction of the anvil, sothat each circular rib or each group of aligned protrusions can beplaced into contact with the insulator sheets on opposite sides of eachconductor element.

In another ultrasonic welding unit, an upstream horn and a downstreamhorn may be provided at a given distance along the direction of motionof the insulator sheets, the horns imparting ultrasonic oscillations,while the corresponding upstream and downstream anvils are likewiseprovided. The upstream and downstream anvils include a contact planewith which is placed into contact one of the insulator sheets. In thethis case, the anvils are fixedly installed. The upstream and downstreamhorns respectively include a oscillation-imparting body having acylindrical form, the axis of which is placed perpendicularly to themoving direction of the insulator sheets. The oscillation-impartingbodies are held around the corresponding axes in a freely rotatable way.The outer circular face of the oscillation-imparting bodies may includean appropriate number of groups of protrusions aligned at a giveninterval in the circumferential direction of the cylindrical body, sothat each group of aligned protrusions can be placed into contact withthe insulator sheets at both sides of each conductor element. Theupstream horn and anvil first form intermittent first welded portions,with a recess between the two welded portions. The downstream horn andanvil then form second welded portions filling those recesses.

In another ultrasonic welding unit, the opposing faces of the horn andanvil respectively include an appropriate number of groups of alignedprotrusions which are arranged so as to be placed into contact with theinsulator sheets at opposite sides of each conductor element. The groupof aligned protrusions is formed along the direction of motion with aninterval which is the same as the moving pitch of the insulator sheets.The groups of aligned protrusions of the horn and anvil flank theinsulator sheets and form intermittent first welded portions on thelatter by ultrasonic welding. The insulator sheets are then moved by theabove-mentioned pitch, and the intervals between the first weldedportions are bonded in the same manner.

In yet another ultrasonic welding unit, one of the horn and the anvil isformed into a plane having a length along the direction of motion of theinsulator sheets. The other includes a cylindrical body having an axisarranged perpendicularly to the direction of motion of the insulatorsheets, such that the cylindrical body can rotate freely around thisaxis. The cylindrical body can further move back and forth along thedirection of motion of the insulator sheets. The outer circular face ofthe cylindrical body includes an appropriate number of continuouscircular ribs which can be placed into contact with the insulator sheetsat both sides of each conductor element.

A third aspect of the invention concerns the flat cables preparedaccording to the methods and by the devices described above.

In the flat cable thus prepared, at least one of the insulator sheets(first insulator sheet) includes an adhesive layer at its inside facewhich faces the other insulator sheet (second insulator sheet). Aplurality of conductor elements are then arranged substantially parallelto one another, and interposed between the adhesive layer and the secondinsulator sheet. The insulator sheets are subsequently pressed againsteach other under heat, and bonded by ultrasonic welding. By virtue ofthis stepwise procedure, the insulator sheets are firmly bonded,although the adhesive layer is made as thin as possible.

As the adhesive layer is made very thin, it can be made of the same typeof material as the base film which contains no halogen-type retardant.The flat cable made thereof thus has a good flame resistance, is easilyrecyclable, and forms no halogen gas when burned.

When one of the insulator sheets has a thickness greater than 1.5 timesthat of the other insulator film (measured for the base film, as thecase may be), the end portions of the flat cable can be very easily madeinto terminals (which are to be inserted into connectors). Namely, thethinner insulator sheet is stripped off from the end portions of theflat cable, while the thicker insulator sheet is kept as it is. Theterminals thus prepared can be inserted easily into the connectors,without being distorted.

In the flat cable thus prepared, both sides of each conductor elementare closed by the welded zones. Therefore, even if water or otherconductor contaminants enter the flat cable, each conductor element isprevented from short-circuiting with other conductor elements.

Although the invention has been described with reference to particularmeans, materials and embodiments, it is to be understood that theinvention is not limited to the particulars disclosed and extends to allequivalents within the scope of the claims.

The present disclosure relates to subject matter contained in priorityJapanese Application Nos. 2000-209759 and 2000-244711, respectivelyfiled on Jul. 11 and Aug. 11, 2000, the disclosures of which are bothherein expressly incorporated by reference in their entireties.

What is claimed:
 1. A method of manufacturing a flat cable having alength and a width, the flat cable comprising first and second insulatorsheets, and at least one adhesive layer interposed therebetween, theflat cable further comprising a plurality of conductor elements arrangedin parallel relation to one another over the length of the first andsecond insulator sheets, said method comprising: providing said adhesivelayer on at least said first insulator sheet so as to face said secondinsulator sheet; interposing said conductor elements between saidadhesive layer and said second insulator sheets; provisionally adheringsaid first and second insulator sheets including said conductor elementsthrough said adhesive layer by a heat pressing force exerted fromoutside said first and second insulator sheets; and bonding, byultrasonic welding, said first and second insulator sheets through thezones extending along said length thereof and located outside the lociwhere said conductor elements are arranged.
 2. The method according toclaim 1, wherein said adhesive-layer providing comprises providing afirst insulator sheet having a thickness of about 12 to about 300 μm andan adhesive layer having a thickness of 1 about to about 3 μm.
 3. Themethod according to claim 1, wherein said adhesive-layer providingcomprises providing an adhesive layer formed of the same type ofmaterial as that of said first insulator sheet, said adhesive layercontaining no halogen-based flame-retardant.
 4. The method according toclaim 1, wherein said adhesive-layer providing comprises providing saidfirst and said second insulator sheets, so that one of said sheets is atleast about 1.5 times thicker than the other.
 5. A system formanufacturing a flat cable having a length and a width, the flat cablecomprising first and second insulator sheets, and at least one adhesivelayer interposed therebetween, the flat cable further comprising aplurality of conductor elements arranged in parallel relation to oneanother over the length of the first and second insulator sheets, saidsystem comprising, along a production flow line from upstream todownstream: an adhesive application unit that provides said adhesivelayer on at least said first insulator sheet so as to face said secondinsulator sheet; a conductor feed unit that interposes said conductorelements between said adhesive layer and said second insulator sheet; aprovisional adhering unit that provisionally adheres said first andsecond insulator sheets including said conductor elements through saidadhesive layer by a heat pressing force exerted from outside said firstand second insulator sheets; and an ultrasonic welding unit that bondssaid first and second insulator sheets through the zones extending alongsaid length thereof and located outside the loci where said conductorelements are arranged.
 6. The system according to claim 5, wherein saidultrasonic welding unit comprises a horn that imparts ultrasonicoscillations, and an anvil located in opposition to said horn; said horncomprises an oscillation-imparting portion, with which one of said firstand second insulator sheets is placed into contact; said anvil comprisesa generally cylindrical form comprising an axis arranged perpendicularlyto said production flow line and being freely rotatable around saidaxis; said generally cylindrical form comprises an outer cylindricalface including an appropriate number of arrays of protrusions, saidprotrusions being aligned in the circumferential direction of said outercylindrical face and extending at a given interval therealong, such thatsaid arrays of aligned protrusions can be placed into contact with theother of said first and second insulator sheets at both sides of each ofsaid conductor elements.
 7. The system according to claim 5, whereinsaid ultrasonic welding unit comprises a horn that imparts ultrasonicoscillations, and an anvil located in opposition to said horn; said horncomprises a plane, with which one of said first and second insulatorsheets is placed into contact over said width hereof; said anvilcomprises a generally cylindrical form that can rotate freely around anaxis, said axis being provided perpendicular to said production flowline; and said anvil comprises an outer circular face including anappropriate number of circular ribs continuously extending in thecircumferential direction thereof, such that said circular ribs can beplaced into contact with the other of said first and second insulatorsheets at both sides of each of said conductor elements.
 8. The systemaccording to claim 7, wherein each of said circular ribs has analternating broad and narrow width.
 9. The system according to claim 5,wherein said ultrasonic welding unit comprises first and second hornsthat impart ultrasonic oscillations, located respectively upstream anddownstream on said production flow line at a given distance, and furthercomprises corresponding first and second anvils located in opposition tosaid first and second horns; said first and second horns respectivelyinclude an oscillation-imparting generally cylindrical body, saidgenerally cylindrical body comprising an axis arranged perpendicularlyto said production flow line and being freely rotatable around saidaxis; each of said oscillation-imparting generally cylindrical bodiescomprises an outer cylindrical face including an appropriate number ofarrays of protrusions aligned in the circumferential direction thereofand extending at a given interval therealong, such that said arrays ofprotrusions can be placed into contact with one of said first and secondinsulator sheets at both sides of each of said conductor elements; saidfirst and second anvils are fixedly positioned and respectively includea plane, with which the other of said first and second insulator sheetsis placed into contact; whereby said first horn and anvil are adapted toform, by ultrasonic welding, a first series of bonded portionsintermittent with a given interval therebetween, and said second hornand anvil then form a second series of bonded portions in said giveninterval.
 10. The system according to claim 5, wherein said ultrasonicwelding unit comprises a horn that imparts ultrasonic oscillations, andan anvil located in opposition to said horn, said horn and anvilincluding respective planes opposing to each other; said opposing planesof said horn and anvil comprise respectively an appropriate number ofarrays, respectively comprised of protrusions and recesses, each of saidprotrusions has the same gauge as each of said recesses along the lengthof said first and second insulator sheets, such that said arrays of saidopposing face of said horn and those of said anvil can be placed intocontact respectively with said first and second insulator sheets at bothsides of each of said conductor elements; such that said first andsecond insulator sheets can be flanked by said arrays comprised ofprotrusions and recesses of said horn and of said anvil, and subjectedto a first ultrasonic welding, thereby forming intermittent first bondedportions; and such that said first and second insulator sheets can bemoved by a distance equivalent to said gauge, and said first and secondinsulator sheets can be further subjected to a second ultrasonicwelding, thereby forming second bonded portions that link said firstbonded portions.
 11. The system according to claim 5, wherein saidultrasonic welding unit comprises a horn that imparts ultrasonicoscillations, and an anvil located in opposition to said horn; one ofsaid horn and said anvil has a plane with a length which extends alongsaid length of said first and second insulator sheets, while the otherincludes a generally cylindrical body comprising an axis arrangedperpendicularly to said production flow line and being freely rotatablearound said axis, said cylindrical body being movable back and forthalong said production flow line; and said generally cylindrical bodycomprises an outer cylindrical face including an appropriate number ofcircular ribs extending in the circumferential direction of said outercylindrical face, so that said circular ribs can be placed into contactwith said first and second insulator sheets at both sides of each ofsaid conductor elements.
 12. The system according to claim 11, whereineach of said circular ribs has an alternating broad and narrow width.13. The system according to claim 11, wherein each of said circular ribsis provided with recesses.